Cost Savings and Efficiency through Power Quality Monitoring. National Instruments

Transcription

1 Cost Savings and Efficiency through Power Quality Monitoring National Instruments

2 Measure It. Fix It. Once you start monitoring something you know you can fix things -Dave Brandt Electrical Engineer NUCOR Steel NI Customer

3 Measure Energy. Reduce Cost.

4 Power Measurements Measure two waveforms with respect to time Voltage Current Calculate RMS Frequency Power Energy

5 Voltage Measurement Black wire (Phase or hot ) White wire (Neutral) NI 9225 Grid Up to 300 V RMS

6 Voltage Measurement NI 9225 Grid Use a potential transformer (PT) for higher voltages Sold by ratio (2:1, 4:1, 5:1, etc) where output 1 = 120 V

7 Current Measurement Electrical Load Grid Solid core NI 9227 Split core Current Transformers are almost always needed Sold by ratios and output either 1A or 5A

8 Power Measurement Power AVG Voltage Inst Current Samples Inst

9 Power Monitoring with NI CompactRIO DEMO Hardware Purpose Specifications NI crio-9024 RT Processing and Control 800 MHz, 512 MB RAM, 4 GB Storage NI 9225 Voltage Measurement 24-bit, 300 V RMS, 50 ks/s/ch NI 9227 Current Measurement 24-bit, 5 A RMS, 50 ks/s/ch Software LabVIEW 2011 Professional Development Environment LabVIEW RT and FPGA Modules LabVIEW Electrical Power Suite Waveform Reference Library (free download)

10 LabVIEW Electrical Power Suite For CompactRIO Hardware Measure power quality and energy features to IEC, EN, and IEEE standards Harmonics (IEC ) Flicker (IEC ) Sag/swell/interruption with standard or custom levels (IEC ) Compatibility with the COMTRADE (IEEE ) file format Download the Evaluation Version: Search for Electrical Power Suite at ni.com PN:

11 PQ Software Created in LabVIEW

12 Why Measure Power Measurement Action Cost Savings Through Total energy consumption Verify with bill from utility Overpayment elimination Sub-metering of energy Assign to cost center Focus on largest energy consumers Demand prediction Power factor Unbalance, RMS trend/level, harmonics, SAG/SWELL Run machines in shifts or alter process control algorithm Run machines in shifts or alter process control algorithm Machine health monitoring Avoid peak usage fees Avoiding fines from utility Energy efficiency and predictive maintenance (machine life, minimize downtime)

13 Sub Metering Use multiple CTs to subdivide energy measurement By building By floor By wing Lighting HVAC

14 Sub Metering Metered Component Organizational Cost Centers (by building, floor etc.) Facility Chillers/Boilers Data Center / Server Room HVAC System Lighting Circuits Compare total energy consumption with monthly bill Example Result R&D department starts turning off computers at night because it is now part of their budget Repair/replace inefficient equipment that consumes the most energy with easy ROI calculations Buy properly sized generator rather than too large to be safe Advanced climate controller installed, OR temperature settings slightly adjusted Change bulb technology Find errors in billing

15 Case Study: Energy Monitoring 15% Energy Reduction Paid for cost of system in 6 months Sub-meters total facility energy Real time data access to Electric grid Diesel generators (energy/fuel) HVAC Lighting and more

16 Why Measure Power Measurement Action Cost Savings Through Total energy consumption Verify with bill from utility Overpayment elimination Sub-metering of energy Assign to cost center Focus on largest energy consumers Demand prediction Power factor Unbalance, RMS trend/level, harmonics, SAG/SWELL Run machines in shifts or alter process control algorithm Run machines in shifts or alter process control algorithm Machine health monitoring Avoid peak usage fees Avoiding fines from utility Energy efficiency and predictive maintenance (machine life, minimize downtime)

17 Avoid Excess Fees and Fines Max energy consumption limits (Energy Demand) Time of Use Billing Power Factor limits

18 Power Factor (PF) Power AVG PF cos V RMS I RMS cos Phase Shift (ɸ) Indicates Reduced Efficiency

19 The Power Triangle Mathematical Analogy Real Power = V * I cos ( ) [Watts] (phi) Apparent Power = V * I [VA] Reactive Power [Var]

20 How Loads Affect Power Factor Inductive Resistive Capacitive Lagging Phase In Phase Leading Phase

21 Power Factor Correction Inductive Capacitive Lagging and leading phases combined will cancel out Lagging Phase Leading Phase

22 Power Factor Correction Adding Capacitive Loads to Inductive Grid Building Installation Substation Installation

23 Case Study: NUCOR Steel One of the largest steel producers in the US, and the largest recycler Implemented grid power monitoring Acted on grid power information Avoided fines Improved power quality Large cost savings Lower environmental impact

24 NUCOR Power Monitoring Station

25 Why Measure Power Measurement Action Cost Savings Through Total energy consumption Verify with bill from utility Overpayment elimination Sub-metering of energy Assign to cost center Focus on largest energy consumers Demand prediction Power factor Unbalance, RMS trend/level, harmonics, SAG/SWELL Run machines in shifts or alter process control algorithm Run machines in shifts or alter process control algorithm Machine health monitoring Avoid peak usage fees Avoiding fines from utility Energy efficiency and predictive maintenance (machine life, minimize downtime)

26 Power Quality Events Sag Swell Interruption Voltage Level (% of nominal) 10%<sag<90%* Duration Instantaneous Cycles Momentary 30 Cycles 3 seconds Temporary 3 seconds 1 minute Voltage Level (% of nominal) 110%<sag<180%* Duration Instantaneous Cycles Momentary 30 Cycles 3 seconds Temporary 3 seconds 1 minute Voltage Level (% of nominal) 110%<sag<180%* Duration Momentary 30 Cycles 3 seconds Temporary 3 seconds 1 minute *Levels differ based on duration. Data pulled from IEEE 1159:1995 See standard for full data.

27 Voltage Unbalance Phase 1 Phase 2 Phase 3

28 Machine Efficiency Cost Example 1800-RPM, 100-hp motor (~74kW) 8,000 hours of operation per year $0.07/kWh 75% load Table from U.S. DOE Energy Efficiency and Renewable Energy Moving the voltage unbalance from 2.5% to 1% would save ~$564/year

29 Voltage Unbalance Fix It. Potential Solutions Fix the phase voltages to match Facility wide Contact utility company Within the facility Run other motors/devices in shifts OR move other machines to balance the three phases Within the motor Repair/replace

30 NI Based Power Monitoring Systems Advantages Access to high speed waveform data Combine with LabVIEW power quality analysis functions Programmable Software Custom diagnostics, analytics User defined interface More than just power measurements Temperature for HVAC Flow and vibration for pumps Torque and RPM for shaft monitoring

31 NI Power Quality Analyzer ELCOM power quality analysis software (powered by LabVIEW) NI CompactRIO embedded hardware Monitor power according to international standards such as IEC X and EN 50160

32 ni.com/power Demo code Tutorials White papers Case studies Sensor recommendations

33 Thank you for attending the NI Embedded Technology Summit For more information, please visit